Multi-Stage Cooling Assembly with Varying Fin Density
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Solution Overview
Problem
Existing charge air coolers with identical fin shapes and spacings can lead to limited heat transfer due to uneven airflow distribution, reducing the effectiveness of heat transfer from air to the intercooler.
Innovation Solution
A multi-stage cooling assembly with independently operable fans and varying fin types and densities across different cooling circuits, allowing for precise control of airflow and coolant flow to enhance heat rejection and temperature control in internal combustion engines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If identical fin shapes and spacings are used in the charge air cooler, then the manufacturing process is simplified, but the heat transfer effectiveness is reduced due to uneven airflow distribution
Solution Approach 1:
The patent applies local quality by varying fin spacing and fin shape characteristics in different regions of the charge air cooler. Specifically, the fin spacing is adjusted based on local airflow patterns and thermal requirements, with denser fins in regions requiring greater heat transfer and wider spacing in regions with higher airflow velocity. This non-uniform fin configuration optimizes heat transfer effectiveness across the entire heat exchanger surface while maintaining manufacturing feasibility through standardized fin profiles.
Solution Approach 2:
The patent implements asymmetry by using different fin spacing arrangements on opposite sides of the heat exchanger core. The first set of fins has a different spacing pattern than the second set of fins, creating an asymmetric overall structure that better matches the non-uniform airflow and thermal load distribution. This asymmetric design improves heat transfer effectiveness without significantly complicating the manufacturing process, as each fin set can still be produced using standard fabrication methods.
2Device complexity
If a single fan is used to provide air flow to the cooling system, then the device complexity is reduced, but the temperature control accuracy deteriorates
Solution Approach 1:
The patent applies segmentation by dividing the air cooling system into multiple independent fan zones, with at least one fan dedicated to serving the charge air cooler and another fan serving the radiator. This segmentation allows each fan to be optimized for its specific function and controlled independently based on local thermal requirements. The controller can adjust each fan's operation based on temperature sensor feedback from respective zones, thereby improving temperature control accuracy without requiring a complete system redesign.
Solution Approach 2:
The patent implements dynamics through independent control of multiple fans based on real-time temperature conditions. The controller monitors temperature in different zones and dynamically adjusts fan operation accordingly - for example, increasing charge air cooler fan speed when intake charge temperature is high while maintaining radiator fan at a different setting. This dynamic, zone-specific control enables precise temperature management that responds to changing operational conditions without requiring excessive system complexity.
3Device complexity
If airflow is directed to only a portion of the charge air cooler surface area, then the device complexity is reduced, but the heat transfer capability is limited
Solution Approach 1:
The patent applies local quality by designing the fin structure to match local airflow characteristics. Different regions of the heat exchanger have fins optimized for their specific airflow conditions - areas with lower airflow velocity have denser fin spacing to maximize heat transfer, while areas with higher velocity have wider spacing. This local optimization ensures that the entire heat exchanger surface area is effectively utilized for heat transfer, maximizing overall heat transfer capability without adding complex airflow distribution mechanisms.
Solution Approach 2:
The patent implements parameter changes by varying fin spacing and fin geometric parameters across different regions of the heat exchanger. The fin spacing parameter is specifically adjusted as a function of position within the heat exchanger core, creating a gradient that optimizes heat transfer across the entire surface area. This parameter variation approach enables the system to fully utilize available heat transfer surface area and improve overall heat transfer capability while maintaining a relatively simple overall structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution increases heat rejection capability and temperature control accuracy by ensuring airflow and coolant distribution across a greater surface area, addressing the limitations of traditional charge air coolers.
Implementation Method 1
a first fan operable to provide air flow to the multi-stage cooling assembly and the air-to-coolant radiator and a second fan that is operable to provide air flow to the air-to-coolant radiator
Implementation Method 2
a multi-stage cooling assembly including an air-to-coolant intercooler for cooling intake air and an air-to-air heat exchanger for cooling intake air
Data Source
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AI summary
Thermal management assemblies and systems related to controlling temperature of internal combustion engines are provided. In one embodiment, a multi-stage cooling assembly includes a body forming an air inlet and an air outlet, a plurality of exterior fins extending outward from an exterior of the body, and an air-to-coolant intercooler positioned in an interior of the body and adjacent the air inlet. The exterior fins differ in fin type, fin density, or both fin type and fin density. In another embodiment, a thermal management system includes an air intake structure defining an air intake passage therethrough coupled to a plurality of cylinders in an engine, a multi-stage cooling assembly positioned in the air intake passage, an air-to-coolant radiator fluidly coupled with the air-to-coolant intercooler of the multi-stage cooling assembly, a first fan operable to provide air flow to the multi-stage cooling assembly and the air-to-coolant radiator, and a second fan operable to provide air flow to the air-to-coolant radiator.